Perforated release tape

ABSTRACT

There is provided a mechanical fastener tape tab laminate capable of remaining closed until needed for use on a disposable garment. A tape tab backing had at least a first distal end portion, an inner tab portion and second distal end portion. The second distal end portion is provided with a mechanical fastener material. The first distal end portion is provided with an adhesive layer for permanent attachment to the disposable absorbent article. The tape tab backing laminate further has a folded tape portion comprising a backing having an adhesive layer on an outer face and at least an inner leg portion and an outer leg portion. The outer leg portion has an exposed adhesive provided for permanent attachment to the disposable absorbent article. The inner leg portion is attached to the tape tab backing so that the folded tape portion keeps the second distal end folded onto the first distal end. The inner and outer leg portions are separated by at least one fold. The folded tape portion backing is provided with a line of weakness along the at least one fold, wherein the line of weakness is provided on a portion of the tape tab backing spaced from the first distal end portion. When the laminate is ready for use, the folded tape portion is broken at the line of weakness allowing the second distal end to be unfolded from the first distal end.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part of application Ser. No. 09/499,136, filedFeb. 7, 2000 now U.S. Pat. No 6,363,587.

BACKGROUND AND FIELD OF INVENTION

The present invention relates to a mechanical fastener closure tape tablaminate for use on disposable articles, generally a disposableabsorbent diaper.

Closure tape tab laminates utilizing mechanical fasteners are known inthe art with the mechanical fastener generally located on a tape tabbacking. The mechanical fastener is attached generally by the use ofadhesives. The opposite end of the tab is generally permanently attachedto one face of the disposable article with the mechanical fastenerextending out beyond a side edge of the absorbent article for use informing a closure with a mating attachment provided on a opposite end ofthe disposable article. Generally when the diaper or the like ispackaged prior to use, it is preferred that the tab be folded back intothe main body of the diaper. Otherwise the tab will extend out beyondthe edge of the diaper and create problems such as inadvertentlyattaching to substrates as well as making it difficult to fold thearticle into a form suitable for an easily packaged product. As such, itis preferred that the mechanical fastener “free end” be folded back ontothe opposite face of the diaper prior to use. The problem of anunattached tab extending out beyond the edge of the diaper is generallyknown as flagging. The conventional approach to solving this flaggingproblem has been to provide a pressure sensitive adhesive somewhere onthe tape tab laminate which would allow the tape tab free end toreleasably adhere to a suitable surface on the diaper. The end userwould then grasp a fingerlift on the tab and break this adhesive bondand extend the tab for use. Such an adhesive antiflagging configurationis disclosed, for example, in European Patent No. 321,232, where theadhesive is adjacent the mechanical fastener on the tab. European PatentApplication No. 894,448 discloses providing pressure sensitive adhesiveon the tops of mechanical fastener hook heads for antiflagging. JapanesePatent Application No. 8-2365 provides adhesive on the extended portionof the tab, which adhesive then transfers to the diaper such that thereis no exposed adhesive on the free end of the tab when in use. The useof an exposed adhesive for antiflagging is also taught in PCT PatentApplication No. WO97/28774. Although effective, the use of an exposedpressure sensitive adhesive is undesirable in many instances with amechanical fastening system. For example there are many exposed fibroussurfaces on absorbent articles with mechanical fasteners, which fibroussurfaces can cause fiber contamination of the adhesive. Also there isundesirable reaction on the part of some customers to the use of exposedadhesives in mechanical fastener systems of this type. For these reasonsand others there has been considerable work on a non-adhesive solutionto the flagging problem.

The use of a non-adhesive approach to the flagging problem is proposed,for example, in European Patent Application No. 818,188. This patentdocument proposes releasably welding the tab free end to an innersurface of a diaper. Although effective, this is problematic in that itrequires an on-line welding during the diaper manufacturing process,which can slow diaper production. Japanese Patent Application No.10-137008 and U.S. Pat. No. 5,926,926 disclose the use of a separatesmall patch of loop material, which can engage with the hooks. Theseloop patches are generally placed where the antiflagging adhesive wouldbe placed. The small loop patches suggested in these patents areunlikely to be entirely effective in providing for a reliableconnection. Also these loops add significant bulk to the tabs creatingthe possibility of hard bands in the packaged diapers and making itdifficult to provide long yardage rolls of prelaminated mechanicalfastener tape tabs. European Patent Application No. 832,631 proposes acomplicated structure involving a splitable nonwoven material. Thiswould have similar issues as the use of loop patches and be difficult tomanufacture. European Patent Application No. 853,935 discloses acomplicated laminated tab structure, which comprises a tape tab backinghaving two adhesive coated portions with an adhesive free regionseparating them and a separate carrier for the hook. The hook carrierhas a separate adhesive attachment zone and is perforated in an adhesivefree zone. The carrier perforation is separable which allows the tab tobe maintained in a folded condition prior to use and broken or torn toallow the tab to be extended. Although effective in maintaining a tab ina folded condition, this construction does not allow for a conventionalY-bond to provide a secure attachment to both faces of the diaper sideedge and requires two complicated zone adhesive coatings on the tape tabbacking and the carrier.

Although there are many varied techniques taught in the art to maintaina fastening tab laminate in a folding condition around the edge of adiaper prior to use, there still remains the need for an effective wayof providing such an arrangement for a mechanical fastener tape tablaminate which provides for a combination of ease of construction, areliable and secure attachment that is easily releasable by the user andwhich does not rely on exposed pressure sensitive adhesives andpreferably in a construction that allows the possibility of providing asecure Y-bond to the edge of the diaper.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a diaper using a tape tab in accordancewith the invention.

FIG. 2 is a perspective view of a diaper roll of a prelaminatedmechanical fastener tape tab of the invention.

FIG. 3 is an exploded view of the first embodiment of a mechanicalfastener tape tab laminate of the invention.

FIG. 4 is an assembled view of the first embodiment mechanical fastenertape tab laminate.

FIG. 5 is an assembled view of the first embodiment mechanical fastenertape tab laminate when initially attached to an article.

FIG. 6 is an assembled view of the first embodiment mechanical fastenertape tab laminate when fully attached to an article.

FIG. 7 is an assembled view of the first embodiment mechanical fastenertape tab laminate in a use form.

FIG. 8 is an exploded view of a second embodiment of a mechanicalfastener tape tab laminate of the invention.

FIG. 9 is an assembled view of the second embodiment of a mechanicalfastener tape tab laminate of the invention.

FIG. 10 is an assembled view of the second embodiment of a mechanicalfastener tape tab laminate of the invention when initially attached toan article.

FIG. 11 is an assembled view of the second embodiment of a mechanicalfastener tape tab laminate of the invention when fully attached to anarticle.

FIG. 12 is an assembled view of the second embodiment of a mechanicalfastener tape tab laminate of the invention in a use form.

FIG. 13 is a third embodiment of a mechanical fastener tape tab laminateof the invention.

FIG. 14 is an assembled view of fourth embodiment of a mechanicalfastener tape tab laminate of the invention.

FIG. 15 is an assembled view of fifth embodiment of a mechanicalfastener tape tab laminate of the invention.

FIG. 16 is an assembled view of sixth embodiment of a mechanicalfastener tape tab laminate of the invention.

FIG. 17 is an assembled view of the seventh embodiment of a mechanicalfastener tape tab laminate of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a conventional diaper construction 1 is showncomprising a liquid permeable topsheet 2 and a liquid impermeablebacksheet 3. Between the topsheet 2 and the backsheet 3 would be anabsorbent pad structure (not shown). The liquid permeable topsheet 2would generally be a nonwoven web or like permeable structure whichwould allow the passage of liquids to the absorbent pad. The liquidimpermeable backsheet 3 conventionally is a film or a laminate of a filmwith a nonwoven. The backsheet film is generally a polyolefinthermoplastic film, which can be provided with breathability. Thenonwoven laminated to such a film would be on the outer surface of thediaper to provide a soft texture and cloth-like feel. The nonwoven canalso provide a surface that could allow a hook material to engage, incertain circumstances, to allow for closure attachment and/ordisposability of the diaper following use. At least a first corner 6 ata first end 7 of the diaper chassis 1 has a mechanical fastener tab 10designed to adhere to a mating mechanical fastener element 4, and/or thefibrous backsheet 3, at a second end 8 of the diaper chassis 1. When thediaper is worn, i.e., when the invention mechanical fastener closure tabis in use, the first corner 6 at the first end 7 of the disposablediaper overlap with a corresponding opposing corner 6 at the opposingend 8 of the diaper so that the corner positions of first end 7 andsecond end 8 of the diaper overlap. Generally mechanical fastening hooksengage with a loop structure and/or possibly the backsheet so that thereis a continuous engagement with the waist of the wearer, encircling thetorso.

The liquid permeable topsheet would comprise a conventional materialknown for this use. These materials include spunbond webs, melt blownwebs, carded webs, and the like. These webs are conventionally formed ofthermoplastic and hydrophobic polymer fibers, such as polyolefin orpolyester fibers.

The backsheet 3 is a generally liquid impermeable web, optionally an airpermeable web or film and conventionally uses a thin polyolefin polymerfilm generally less than 1 to 2 mils thick. For use in a mechanicalfastener closure system, the backsheet 3 is preferably a laminate of asubstantially liquid impermeable film with a woven, nonwoven, knitted orstitch bonded or like fibrous web, which fibrous web is suitablyengageable with the mechanical fastener hooks 11 on the mechanicalfastening tab 10. Adhesive lamination, pattern heat bonding or extrusionlamination of the web with the liquid impermeable film can form thislaminate.

The loop material can be any conventional loop fabric such as disclosed,for example, in U.S. Pat. Nos. 5,176,670 or 5,256,231, the substance ofwhich are incorporated herein by reference. The loop fabric can be aconventional fibrous structure such as a nonwoven, a knitted material, astitch bonded material or the like, formed of natural or syntheticfibers, which fibers can be either continuous or discontinuous and/orbonded. Generally, the loop material must have sufficient availablefibers and loft to allow penetration of the mechanical fastening 11 intothe loop structure but still have enough fibers available to engage withthe individual hooks.

The mechanical fastener of the invention would generally comprise a tapebacking 13 having a hook element 11 where the backing is provided with adistal finger-lift region 12. The backing 13 would further include arelease tab 15 that would preferably cover an inner tab portion 14 ofthe tape tab backing and is preferably also bonded to the topsheet 2 atthe corner portion 6 at the first end 7 of the diaper. Mechanicalfastener tape tab laminates 10 of the invention can be provided in aroll form as is generally shown in FIG. 2. This roll is generallyprovided with a mechanical fastener tape tab laminate having a fingerlift 22, a mechanical fastener portion 21 and a release tab 25.Individual tab elements 23 can be cut from the roll and attached to thediaper in a manner which will become clear upon discussion of thefurther specific embodiments below.

A first embodiment of the invention mechanical fastener tape tablaminate is shown in the expanded view of FIG. 3. The tape tab backing33 is provided with a pressure-sensitive adhesive layer 36, whichadhesive layer allows for attachment of the mechanical fastener material31 and the release tab 35. Optionally, a further adhesive layer 38 canbe provided on the mechanical fastener material 31. The tape tab backing33 is separated into three distinct portions. The first distal endportion 37 is provided with an exposed portion of the adhesive layer 36,which exposed adhesive is used for permanent attachment of the assembledtab to one face of the diaper chassis 1. An inner tab portion 34 isattached to the release tab 35 using the adhesive layer, 36 and 44. Asecond distal end portion 39 of the tape tab backing 33 is provided withthe releasably fastenable mechanical fastener material 31 and optionallya finger lift 32. The mechanical fastener material 31 is attached usingadhesive layer 36 and/or an adhesive layer 38 on the mechanical fastenerelement 31. Generally, the tape tab backing 33 is provided with acontinuous pressure-sensitive adhesive layer 36 for ease ofmanufacturability. However, the inner tab portion 34 and the seconddistal end portion 39 need not be provided with pressure-sensitiveadhesive provided that the mechanical fastener material 31 and/or therelease tab 35 are provided with suitable adhesives or otherconventional attachment means to attach to the backing 33. Generally,pressure-sensitive adhesives are preferred for attachment of themechanical fastener material 31 and release tab 35, however, othersuitable conventional methods, such as thermal point bonding or heatactivatable adhesives could be used if suitable. In the preferredembodiment, the mechanical fastener material 31 is a hook element 11generally provided with upstanding hook elements for engagement with amating loop surface provided on the outside of the diaper, generally,the loop fastener element 4. Although generally not economically viable,alternatively, a loop fastening material could be used in place of thehook element 11 as the mechanical fastener material 31, provided asuitable hook material was provided on the front portion of the diaper1. Other known mechanical fastening structures could also be suitablefor the invention laminates such as self-mating fasteners.

The release tab 35 generally comprises a backing 47 provided with apressure-sensitive adhesive layer 44 on the outer face. The oppositeinner face 46 of the backing can be provided with a suitable releaselayer or treatment, however such a release layer or treatment isoptional. The release tab 35 in the FIG. 3 embodiment is folded into acircular form provided with an inner fold 41 and an outer fold 42. Theinner fold 41 would be adjacent the edge on a diaper 1 when the tabportion first distal end 37 is attached to the diaper (e.g., backsheet3). Generally, the release tab 35 comprises a flat film, or like web,folded into a circular form having ends 45. These ends 45 meet to formthe circular form on the side of the folded structure directly attachedto the tape tab backing 33. Thus, both ends 45 are attached to the tapetab backing 33. This ensures that the release tab backing is asubstantially continuous uninterrupted circular structure when therelease tab is attached to the backing 33 in the laminate. Specifically,the release tab 35 is a substantially continuous (no gaps that wouldallow the release tab 35 to be opened or unfolded) structure, from theinner fold 41 to the outer fold 42 and back again, when the release tab35 is attached to the tape tab backing 33 as shown in FIG. 4. Thecircular structure of the release tab when attached to the backing 33has an outer leg 52 and an inner attached leg 51. The outer fold 42 isprovided with a weakened zone 43 which allows the release tab to beeasily broken at this point. Generally, this line of weakness isprovided by suitably cutting the release tab backing 47 intermittentlyalong the line 43 along the width dimension of the release tab backing.The backing 47 remains continuous and attached along this line ofweakness to allow the release tab to be folded and remain folded andcontinuous prior to use. The line of weakness could also be formed byscoring, partially cutting through backing 47, or otherwise weakeningbacking 47 along line 43 across substantially the entire width of thebacking 47.

FIG. 4 shows the assembled laminate as shown in the expanded view ofFIG. 3, where like numerals indicate identical elements. The seconddistal end portion 39 of the tape tab backing 33 has been folded overonto itself to provide a finger lift portion 32 and the mechanicalfastener material 31 and the release tab 35 are in substantiallyabutting relationship. This allows the mechanical fastener material 31and the release tab 35 to cover the entire adhesive layer 36 on thesecond distal end portion 39 and the inner tab portion 34.Alternatively, the mechanical fastener material 31 and the release tab35 could be spaced from each other if there is substantially no exposedadhesive in the gap formed, for example if there is no adhesive layer 36on second distal end portion 39 and/or the inner tab portion 34 of thetape tab backing 33.

The first embodiment of the tape tab laminate 40 is shown partiallyattached to a diaper chassis 1 in FIG. 5. The tape tab backing 33 firstdistal end portion 37 is attached to the diaper corner 6 by thepressure-sensitive adhesive layer 36. The edge 5 of the diaper cornerportion 6 substantially abuts the release tab inner fold 41 as shown,however this is not necessary. It is generally sufficient that the firsttab distal end portion 37 has sufficient adhesive surface area incontact with the diaper corner 6 so as to provide a secure engagement.The available surface area of adhesive layer 36 and the first endportion 37 is attached to the diaper when the diaper edge 5 is close toor abutting the release tab inner fold 41.

FIG. 5 depicts an intermediate step in the attachment of the mechanicalfastener tape tab laminate 40 to the diaper chassis 1. The completedattachment of the laminate 40 to a diaper is shown in FIG. 6 where thetape tab backing 33 is folded over back onto itself on the opposite sideof the corner portion 6 so that the pressure-sensitive adhesive 44 onthe outer leg 52 of the release tab attaches to the opposite face of thecorner portion 6 securing the mechanical fastener tape tab laminate 40in the folded condition. The mechanical fastener tape tab laminate 40remains in this folded condition up to the point in time that the diaperis used. When the diaper is used, the folded over portion of the tapetab laminate 40, comprising the second distal end portion 39 and theinner tab portion 34, is extended from its folded condition at thecorner 6 of the diaper by breaking the release tab 35 along the weakenedline. The mechanical fastener material 31 is then exposed for use asshown in FIG. 7 without any exposed adhesive 36. Generally, to ensurethat the laminate is maintained in its folded over condition prior touse, the line of weakness is located at least 10 mm, preferably at least15 mm, from where the tape tab laminate is folded 49 back onto itself.

In the embodiment of FIGS. 3-7 the second distal end portion 39 of thetape tab backing 33 is effectively bonded to both faces of the diaper 1at the diaper corner portion 6 by attachment of the first distal endportion 37 of tape tab backing 33 and by attachment of the outer leg 52of the release tab 35 to the opposite face of the diaper corner portion6. The shear forces exerted by attachment of the mechanical fastenermaterial 31 to the loop or opposing mechanical fastener material on thediaper chassis are transferred to both faces of the diaper by theattachment of both the release tab 35 and the backing 33 to the diaper.These forces are transferred from the backing 33 to the release tab 53via the continuous inner fold 41, which provides what is generallycalled a “Y-bond”. The use of a Y-bond fold 49 and its advantages aredescribed, for example, in U.S. Pat. Nos. 3,848,594 and 4,726,971 andPCT Appln. No. WO/IUS96/12464, the substance of which are substantiallyincorporated herein by reference. The Y-bond fold 49 provides a verysecure, permanent attachment of the mechanical fastener tape tablaminate 40 to the diaper chassis 1 minimizing or eliminating the riskof detachment and providing an even distribution of the attachmentforces to both faces of the corner portion 6 of the diaper 1.

A second embodiment of the invention mechanical fastener tape tablaminate 50 is shown in FIGS. 8-12. An expanded view of the secondembodiment of mechanical fastener tape tab laminate 50 is shown in FIG.8. The tape tab backing 53 is provided with a pressure-sensitiveadhesive layer 56 that allows for attachment of the mechanical fastenermaterial 31, which mechanical fastener material 31 can optionallycontain a further adhesive layer 38, and the release tab 55. The tapetab backing 53 is separated into four portions. The first portion is thefirst distal end portion 57 which is provided with an exposed portion ofthe adhesive layer 56 for permanent attachment to the diaper chassis 1.The second portion is an inner tab portion 54 which is attached to therelease tab 55. The third portion is the second distal end portion 59 ofthe tape tab backing 53 which is provided with the releasably fastenablemechanical fastener material 31. The fourth portion is the finger liftportion 52, which also has an exposed portion of the adhesive layer 56.

Generally, the tape tab backing 53 is provided with a continuouspressure-sensitive adhesive layer 56 for ease of manufacturability.However, the inner tab portion 54 and the second distal end portion 59need not be provided with pressure-sensitive adhesive provided that themechanical fastener material 31 and/or the release tab 55 are providedwith suitable adhesive or other conventional means to attach to thebacking 53. The adhesive layer 56 could be intermittently provided onthe tape tab backing 53 only in those areas where it is needed. Themechanical fastener material 31 is generally provided with upstandinghook elements suitable for engagement to the mating surface provided onthe outside of the diaper, generally, the loop fastener element 4.

The release tab 55 generally comprises a backing 75 provided with apressure-sensitive adhesive layer 58 an outer face 76. The oppositeinner face 77 of the backing can be provided with a suitable releaselayer or treatment, however such is optional. The release tab 55 isfolded into a C-shape provided with an inner fold 60 and an open end 61.The inner fold 60 would generally be adjacent the edge 5 on a diaperwhen the first distal end portion 57 is attached to the diaper cornerportion 6. Generally, the release tab 55 backing 75comprises, a flatfilm or like web having ends 62, which ends 62 can terminate adjacentthe mechanical fastener material 31. Generally only the bottom leg 72 ofthe C-fold release tab 55 needs to terminate near or adjacent themechanical fastener material 31 of the inner tab portion 54 when thereis an underlying pressure sensitive adhesive layer 56. If pressuresensitive adhesive layer 56 is not provided in the inner tab portion,the location of the release tab 55 ends 62 is not critical as noadhesive needs to be covered, and in certain embodiments release tab 55could be eliminated or be a flat unfolded film only covering the innertab portion 54. The tape tab backing 53 in the finger lift portion 52 isfolded back onto itself in a Z-shape providing an outer top leg 74,having an exposed portion of adhesive layer 56, and an inner leg 73. Thebottom leg of the Z-shape is the unfolded main portion of the tape tabbacking 53. The inner leg 73 is created by a first fold 64 of thebacking 53. The second outer leg 74 is created by a second fold 65 ofthe inner leg 73. The outer leg 74 is designed to attach to a surface ofthe diaper by the exposed portion of adhesive layer 56 as shown in FIG.11. The outer fold 65 is provided with a weakened zone 66, which allowsthe Z fold finger lift 52 to be easily broken at this point. Generally,this line of weakness is provided by suitably cutting the tape tabbacking intermittently along the line 66 or as otherwise discussedrelative to the first embodiment. FIG. 9 shows the assembled laminateshown in the expanded view, where like numerals indicate identicalelements.

The second embodiment of the tape tab laminate 50 is shown partiallyattached to a diaper chassis 1 in FIG. 10. The tape tab backing 53 firstdistal end portion 57 is attached to the diaper corner 6 by thepressure-sensitive layer 56. The edge 5 of the diaper corner portion 6substantially abuts the release tab fold 60. However, again it isgenerally only sufficient that the first distal end portion 57 hassufficient adhesive surface area in contact with the diaper corner 6 soas to provide a secure engagement.

FIG. 10 is an intermediate step in the process of attaching the tape tablaminate 50 to the diaper chassis 1. The completed attachment of thesecond embodiment tape tab laminate 50 is shown in FIG. 11 where thetape tab backing 53 is folded over back onto itself on the opposite sideof the corner portion 6 so that the pressure-sensitive adhesive 67 onthe finger lift 52 attaches to the opposite face of the corner portion 6securing the laminate 50 in the folded condition. The mechanicalfastener tape tab laminate is provided in this folded condition up tothe point in time that the diaper is used. When the diaper is used, thefolded over portion of the tape tab laminate comprising the inner tabportion 54 the second distal end portion 59 and the fingerlift portion,are separated from the corner 6 of the diaper by breaking the fingerlift portion 52 along the weakened line 66. The mechanical fastenermaterial 31 is then exposed for use as shown in FIG. 12. The outer leg74 remains attached to the diaper but with the adhesive not exposedduring use of the mechanical fastening tab laminate 50.

Again, in the embodiment of FIGS. 8-12, the second distal end portion 59of the tape tab backing 53 is effectively bonded to both faces of thediaper 1 at the corner portion 6 in a Y-bond 68, by attachment of boththe first distal end tab portion 57 of a tape tab backing and outer legportion 71 of the release tab 55. The shear forces exerted by attachmentof the mechanical fastener element 31 to the loop or opposing mechanicalfastener on the diaper chassis are transferred to both faces of thediaper as the release tab 55 is attached to both the backing 53 and thediaper by the inner fold 60 which provides a Y-bond 68. The forces fromthe tape tab backing 53 are transferred to the diaper from the inner leg72, attached to the backing 53, to the outer leg 71, attached to thediaper.

A third embodiment of the invention mechanical fastener tape tablaminate 80 is shown in FIG. 13. The tape tab backing 83 is providedwith a pressure sensitive adhesive layer 86 which allows for theattachment of the mechanical fastener material 31, which can optionallycontain a further adhesive layer 38, and the release tab laminate 95.The tape tab backing 83 is separated into three portions. The firstportion is the first distal tab end portion 87 which is provided with anexposed portion of the adhesive layer 86 for permanent attachment to oneface of the diaper chassis 1. The second portion is an inner tab portion84 which is attached to the release tab 95. The third portion is thesecond distal end portion 89 of the tape tab backing 83 which isprovided with the releasably attachable mechanical fastening material31. A separately attached web layer 99 attached to the adhesive layer 86of the tape tab backing 83 provides the optional finger lift 82. Therelease tab of the embodiment of FIG. 13 differs from the firstembodiment of the invention, shown in FIGS. 3-7, in that the release tabbacking 97 is folded into a C-fold shape having a first inner leg 91 anda second outer leg 92 on opposite sides of a C-fold 94. The first innerleg 91 of the C-folded release tab is attached to the diaper tape tabbacking 83. The second outer leg 92 is not attached to the tape tabbacking. The release tab laminate 95 then forms an inner fold 98 by useof a separately attached unifying web 96 forming a tape tab laminate.The unifying web 96 is attached at one face to the second outer leg 92of the release tab at a terminal end portion of this second outer leg92, and attached to tape tab backing 83 on an opposite face of theunifying web 96. Between the two points of attachment, the unifying web96 is folded into a C-shape providing an inner fold 98. This inner fold98 creates a Y-bond as described in the first embodiment of U.S. Pat.No. 4,726,971, the substance of which is incorporated by reference inits entirety. A. In the FIG. 13 embodiment the release tab 95 laminatedwith unifying web 96 is a substantially continuous structure from theinner fold 98 provided by the unifying web 96 to the outer C-fold 94provided by the release tab. The outer C-fold 94 is provided with aweakened zone 93 which allows the release tab to be easily broken atthis point after assembled into a diaper as shown in FIG. 1, and thefirst embodiment FIG. 7.

A fourth embodiment of the invention mechanical fastener tape tablaminate 100 is shown in FIG. 14. The tape tab backing 103 is providedwith a pressure sensitive adhesive layer 106 that allows for attachmentof the mechanical fastener material 31, which can optionally contain afurther adhesive layer 38, and the release tab 105. The tape tablaminate 100 is provided with four portions. The first portion is thefirst distal end portion 107 which is provided with an exposed adhesiveportion of the adhesive layer 106 for a permanent attachment to one faceof the diaper chassis 1. The second portion is an inner tab portion 104which is attached to the release tab 105. The third portion is thesecond distal end portion 109 of the tape tab backing 103 which isprovided with the releasably fastenable mechanical fastener material 31.The fourth portion is a fingerlift portion 112 provided with thebreakable line of weakness 113 providing the invention antiflaggingfeature.

The finger lift portion 112 is provided with a C-folded tape element118. The C-folded tape element 118 comprises a backing 116 having afirst inner leg 111 and a second outer leg 117 separated by fold 115.The second outer leg 117 has an exposed adhesive 114 and the fold 115 isprovided with a weakened zone 113, which allows the C-folded tapeelement 118 to be easily broken at this point. The exposed adhesivelayer 114 on the C-folded tape element 118 allows attachment to theopposite face of the diaper corner portion 6 securing the laminate 100in a folded condition such as shown in the second embodiment of theinvention. An adhesive-free fingerlift is provided by web 99 as in theFIG. 13 embodiment. The mechanical fastener tape tab laminate 100 isprovided in this folded condition up to the point in time that thediaper is used. When the diaper is used the folded over portion of thetape tab laminate comprising the inner tab portion 104, the seconddistal end portion 109 and the fingerlift portion 112 are separated fromthe corner 6 of a diaper by breaking the C-fold tape element 118 alongthe weakened line 113. The mechanical fastener material 31 is thenexposed for use. In this embodiment a Y-bond is not formed in that therelease tab 105 is attached only to the tape tab backing 103. TheC-folded tape element 118 could also be arranged in the oppositedirection such that the open end of the C-fold faces out towards thefree fingerlift. Also the first inner leg 111 could be formed by theunfolded tape tab backing 103.

The embodiment of FIG. 15 is a variation of the second embodiment of theinvention where a Y-bond is not created in that a release tab 105 isprovided only to cover exposed adhesive on the inner tab portion of thetape tab backing in this embodiment. Like numbers specify identicalfeatures of the second embodiment of FIGS. 8-12.

A sixth embodiment of the invention is shown in FIG. 16. In thisembodiment the release tab 125 is provided in a C-fold. An inner leg 122is attached to the tape tab backing 33 and folded along fold 126 to anouter leg 121, which is provided with an exposed adhesive 127 forattachment to an opposing face of the diaper corner 6. The fold 126 isprovided with a line of weakening 123. In this embodiment a Y-bond willnot be created in that when the line of weakening 123 is broken theouter leg portion 121 of the release tab would be attached only to theinner face of the diaper and not to the tape tab backing 33.

A seventh embodiment of the invention is shown in FIG. 17. In thisembodiment, the release tab 135 is similar to that shown in the firstembodiment except that the tape tab backing 140 is provided with anelastic section 147. Preferably, the two distal end portions of the tapetab backing 140 are inelastic, namely the distal end 148 provided withthe mechanical fastener materials 31 and the opposing distal end 149provided with adhesive layer 146 for permanent attachment of theassembled tab to the diaper chassis 1. The adhesive layer 146 ispreferably only provided on the distal end 149 and optionally on distalend 148 but preferably not central elastic portion 147.

The release tab 135 is folded into a circular form with an inner fold136 and an outer fold 137. The release tab is a substantially continuousstructure, as in the first embodiment, when attached to the backing. Theouter leg 131 is connected to two inner legs 133, having terminal ends139, by the two folds 136 and 137. The outer fold 137 is provided with aweakened zone 138 which allows the release tab 135 to be easily brokenat this point. The tape tab backing 140 is not covered with an adhesivelayer 146, as shown, on the distal end 148 and on the center elasticsection 147 so the mechanical fastener material 31 and the release tab35 can be placed in spaced apart locations without a concern of exposedadhesive.

As in the first embodiment, when the diaper is used, the folded overportion of the tape tab laminate, comprising the second distal endportion 148 and the distal end portion 149, is extended from its foldedcondition at a corner of the diaper by breaking the release tab 135along the weakened line 138. The mechanical fastener material 31 is thenexposed for use as shown in FIG. 7. Further, the elastic central section147 is exposed between the two terminal ends 139 of the two inner legportions 133 of the release tab 135. The two terminal ends 139 arepreferably separated by given distance, generally about 1 to 4 cm,preferably 2 to 3 cm, to provide sufficient elastic function to the tapetab laminate. The tab in use as such is elastic by the elastic section147 of the tape tab backing 140. The tape tab backing can be providedwith an elastic section 147 by any known method in the art and ispreferably elastic only between the terminal ends of the inner legportions 133 and not at those portions of the tape tab backing attachedto the inner leg portion 133. Relevant methods of providing a tape tabbacking with an elastic center section include U.S. Pat. Nos. 3,800,796;4,074,716; 4,778,701; 4,787,897; 4,795,456; 5,057,097; 5,182,156;5,344,691; and 5,620,780, the substance of which are incorporated byreference. A further example of a side-by-side coextrusion of a backinghaving an elastic midsection and inelastic end sections is described inJapanese Kokai 8-187,113 published Jul. 23, 1996. Generally tab backingswith elastic sections can be provided by coextrusion of a section thathas, or is modified to have, preferential elastic properties oralternatively an elastic material is laminated to one or more inelasticmaterials. A preferred method of providing an elastic center section ina laminate construction is described in WO99/48455 (corresponding toU.S. application Ser. No. 09/049,727 now U.S. Pat. No. 6,159,584 thesubstance of which is incorporated by reference) which is the backingmaterial 140 shown in FIG. 17. The tape tab backing 140 comprises acoextruded elastic film formed of an elastic layer 142 and one or moreouter inelastic layers, 145 and 144 on the outer face of the elasticlayer 142. The coextruded elastic film is laminated to a nonwoven layer141 which is extensible in at least one section to create the elasticportion 147 of the backing 140 and is relatively inextensible in theareas forming the relatively inelastic distal end portions 148 and 149.The relative extensibly of the nonwoven determines the location of theelastic and inelastic portions of the laminate. The nonwoven 141 can bemade to be extensible by mechanical means, such as by formingcorrugations, as shown in FIG. 17, or by other known methods. Thecoextruded elastic film backing 140 and the nonwoven layer 141 can beattached by heat bonding, extrusion bonding, adhesive bonding and thelike. Alternatively, the elastic backing 140 could be a single layerelastic film.

The above detailed description of the invention is made with respect tocertain preferred embodiments of the invention mechanical fastener tapetab closure laminate as used on a conventional disposable diaperchassis. However, it would be apparent to one of skill in the art thatthe preferred embodiments of the invention mechanical fastener tape tabclosure laminate could be equally applicable to other articles such ashospital gowns, caps, incontinent garments and other diaper designs andthe like.

We claim:
 1. A mechanical fastener tape tab laminate comprising a tape tab backing having at least a first distal end portion, an inner tab portion and second distal end portion, the second distal end portion provided with a mechanical fastener material, the first distal end portion provided with an adhesive layer for attachment to a disposable absorbent article, the tape tab backing further having a folded tape portion comprising a backing having an adhesive layer on an outer face and having at least an inner leg portion and an outer leg portion, the outer leg portion having an exposed adhesive provided for attachment to the disposable absorbent article, the inner and outer leg portions separated by at least one fold, the folded tape portion backing having a line of weakness along the at least one fold, wherein the line of weakness is provided on a portion of the tape tab backing spaced from the first distal end portion and wherein the folded tape portion has an outer leg portion and two inner leg portions having terminal ends which are separated by a distance and wherein the tape tab backing is elastic for at least a portion of the distance between the terminal ends of the two inner leg portions.
 2. The mechanical fastener tape tab laminate of claim 1 wherein the distance between the two terminal ends is from 1 to 4 cm.
 3. The mechanical fastener tape tab laminate of claim 2 wherein the distance between the two terminal ends is from 2 to 3 cm.
 4. The mechanical fastener tape tab laminate of claim 1 wherein the tape tab backing is elastic only in the region between the terminal ends of the two inner leg portions.
 5. The mechanical fastener tape tab laminate of claim 1 wherein the tape tab backing is a laminate of an elastic film and a nonwoven wherein the nonwoven has at least one extensible portion and at least one relatively inextensible portion.
 6. A disposable absorbent article having a mechanical fastener tape tab laminate, the disposable absorbent article having an outer face and an inner face at least one edge having a mechanical fastener tape tab laminate at one terminal end, said mechanical fastener tape tab laminate comprising a tape tab backing having at least a first distal end portion, an inner tab portion and second distal end portion, the second distal end portion provided with a mechanical fastener material, the first distal end portion provided with an adhesive layer for attachment to a disposable absorbent article, the tape tab backing further having a folded tape portion comprising a backing having an adhesive layer on an outer face and having at least an inner leg portion and an outer leg portion, the outer leg portion having an exposed adhesive provided for attachment to the disposable absorbent article, the inner and outer leg portions separated by at least one fold, the folded tape portion backing having a line of weakness along the at least one fold, wherein the line of weakness is provided on a portion of the tape tab backing spaced from the first distal end portion and wherein the folded tape portion has an outer leg portion and two inner leg portions having terminal ends which are separated by a distance and wherein the tape tab backing is elastic for at least a portion of the distance between the terminal ends of the two inner leg portions.
 7. The disposable absorbent article of claim 6 wherein the distance between the two terminal ends is from 1 to 4 cm.
 8. The disposable absorbent article of claim 7 wherein the distance between the two terminal ends is from 2 to 3 cm.
 9. The disposable absorbent article of claim 6 wherein the tape tab backing is elastic only in the region between the terminal ends of the two inner leg portions.
 10. The disposable absorbent article of claim 6 wherein the tape tab backing is a laminate of an elastic film and a nonwoven wherein the nonwoven has at least one extensible portion and at least one relatively inextensible portion. 